Forklifts are one of the most commonly used material handling devices in almost every industry due to their versatility and convenience. But, convenience comes with a price, sprains and strains related to forklift use have been associated with the highest number of lost workdays.

The risk factors and suggested improvement options outlined below are general to forklift operations. The intent here is to offer educational and injury prevention information for forklift operator.

Poor visibility and awkward postures

A recent study showed that 81% of the forklift operators reported discomfort due to the awkward postures required to look around the load that often obstructs visibility. To compensate, operators often drive in reverse, which places the neck, shoulders and back in an even more awkward position. This sort of twisting and turning has been linked to serious long-term injuries.

Vibration

Forklift operators have a high risk of developing musculoskeletal problems due to Whole-body Vibration (WBV), combined with the awkward seated postures and the repetitive nature of driving a forklift. Long-term exposure to WBV has been known to cause damage to the lumbar area (low back) when exposure is continuous. Variables related to the severity of vibration and the forklift include: weight of the forklift, style of wheels, type of seating, floor surface, and whether the forklift is loaded or unloaded.

The following are suggested improvement options to reduce vibration specific to the forklift and environment:

• Slower driving
• Heavier loads create less vibration versus driving with light or empty loads
• Inflatable, pneumatic tires (pressurized with compressed air) have "proven" to reduce vibration (Kerst et al, 1993)
• Smooth surface (concrete). Vibration can be up to 70% greater on rough surfaces.
• Anti-vibration seat and a normal seat are dependent upon the type of tire used

Awkward postures and limited range of motion from seatbelt use

The most common cause of death with forklifts is when an operator attempts to jump clear of an overturning forklift and is crushed. The safest place for the operator is in the cabin, restrained by a seatbelt. However, snug fitting seatbelts can restrict the operator’s movement, limiting comfortable turning, twisting, and hip shift techniques. While wearing a seatbelt loose around the hips may be more comfortable, it may not protect the operator during a collision or tip over.

• It is critical to ensure through policy and reinforcement that operators wear their seatbelt while operating the forklift. To improve comfort and improve ranges of motion consider retractable seatbelts. Retractable lap/shoulder belts would be the most beneficial for keeping operators contained within the cab in the event of an accident. The retractable belt would allow the operator to shift as needed and may convince more operators to use the belts properly.

References

• The Ergonomics of Lift Trucks: Technical Report, Pulp and Paper Health & Safety Association, http://www.pphsa.on.ca/, 1998 Cal/OSHA, www.dir.ca.gov/Title8/3668.html